Construction structure and method for producing same

ABSTRACT

A construction structure  1  includes a plurality of lengthened members  2  located to make individual longitudinal directions of the members parallel to each other in a first direction D 1  and to be arranged side by side in a second direction D 2  orthogonal to the first direction D 1 , and a panel  3  fittable to between the lengthened members  2,2 , wherein the panel  3  is a foam having a plurality of cells  31  formed lengthwise along a direction orthogonal to the second direction D 2  to have elasticity in the second direction D 2.

TECHNICAL FIELD

The present invention relates to a construction structure in which one or more panels are fitted to between a plurality of lengthened members arranged side by side, and a method for producing the construction structure.

BACKGROUND ART

Hitherto, as a construction structure, known has been a construction structure having the following: a plurality of lengthened members (for example, columns) arranged side by side in the widthwise direction of the members to make individual longitudinal directions of the members parallel to each other; and hard panels fittable to between the lengthened members (for example, Patent Document 1). For example, the panels are each a heat insulating member made of a synthetic resin.

In this construction structure, the panels are required to have a high dimension precision. Specifically, even when the dimension of any one of the panels is slightly small, a gap is generated between the panel and ones adjacent thereto out of the lengthened members. Contrarily, even when the dimension of the panel is slightly large, the panel is not fitted to between the adjacent lengthened members or the panel that has been fitted to therebetween by force is damaged.

PRIOR ART DOCUMENT Patent Document

Patent Document 1: JP-A-2003-278290

SUMMARY OF THE INVENTION Problems to be Solved by the Invention

Thus, in light of the situation, an object of the present invention is to provide a construction structure making it possible to fit its panel easily to between its lengthened members, and prevent any gap from being generated between the panel and one adjacent thereto out of the lengthened members.

According to the present invention, there is provided a construction structure, which includes:

a plurality of lengthened members located to make individual longitudinal directions of the members parallel to each other in a first direction and to be arranged side by side in a second direction orthogonal to the first direction; and

a panel fittable to between the lengthened members;

wherein the panel is a foam having a plurality of cells formed lengthwise along a direction orthogonal to the second direction to have elasticity in the second direction.

According to the construction structure of the present invention, its lengthened members are located to make individual longitudinal directions of the members parallel to each other in a first direction and to be arranged side by side in a second direction orthogonal to the first direction. Its panel is a foam having a plurality of cells formed lengthwise along a direction orthogonal to the second direction, so as to have elasticity in the second direction. Accordingly, the panel compressed in the second direction is released from the compression between ones adjacent of the lengthened members, so as to be restored (or the panel is fitted to between the adjacent lengthened members while compressed in the second direction), so that the panel is fitted to between the adjacent lengthened members in the state of contacting the adjacent lengthened members closely and pushing the adjacent lengthened members.

Also, the construction structure according to the present invention may have a configuration in which:

the cells are formed lengthwise along the first direction to make the elastic modulus in the second direction of the panel smaller than that in the first direction of the panel.

According to this configuration, the cells are formed lengthwise in the direction orthogonal to the second direction, so that the elastic modulus in the second direction of the panel becomes small. In this way, the panel has elasticity in the second direction to be easily compressed in the second direction. Furthermore, the cells are formed lengthwise along the first direction out of directions orthogonal to the second direction. Accordingly, the panel becomes large in elastic modulus in the first direction. Thus, the panel has rigidity in the first direction, so that the panel between the adjacent lengthened members is stably held between the adjacent lengthened members.

According to the present invention, there is provided a method for producing a construction structure, which includes:

preparing a plurality of lengthened members located to make individual longitudinal directions of the members parallel to each other in a first direction and to be arranged side by side in a second direction orthogonal to the first direction; and

fitting a panel to between the lengthened members, the panel being a foam having a plurality of cells formed lengthwise along a direction orthogonal to the second direction to have elasticity in the second direction.

As described above, the present invention produces excellent advantageous effects that the panel is easily fittable to between the adjacent lengthened members and further a gap is prevented from being generated between the panel and the lengthened members adjacent thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front view of a main portion of a construction structure according to an embodiment of the present invention.

FIG. 2 illustrates a sectional view taken on line II-II in FIG. 1.

FIG. 3 illustrates a perspective view of the whole of the panel according to the embodiment.

FIG. 4 illustrates an enlarged sectional view of a main portion (of the panel) taken on line IV-IV in FIG. 3.

FIG. 5 illustrates a perspective view of a main portion (of a panel workpiece) that is referred to for describing a method for producing the panel according to the embodiment.

FIG. 6 illustrates a perspective view of a main portion (of a structure workpiece) that is referred to for describing a method for producing the construction structure according to the embodiment.

FIG. 7 illustrates a front view of a main portion of a construction structure according to another embodiment of the invention.

FIG. 8 illustrates a transversely sectional view of a main portion of a construction structure according to still another embodiment of the invention.

FIG. 9 illustrates a transversely sectional view of a main portion of a construction structure according to a different embodiment of the invention.

FIG. 10 illustrates a transversely sectional view of a main portion of a construction structure according to a further different embodiment of the invention.

FIG. 11 shows a table for evaluation of examples of the invention.

MODE FOR CARRYING OUT THE INVENTION

With reference to FIGS. 1 to 6, a description will be made about a construction structure according to an embodiment of the present invention.

As illustrated in FIGS. 1 and 2, the construction structure according to the present embodiment, which is a construction structure 1, has a plurality of lengthened members 2 (two members are illustrated in each of FIGS. 1 and 2) located to make individual longitudinal directions of the members parallel to each other, and to be arranged side by side in the widthwise direction thereof; and a panel 3 fitted to between adjacent ones 2, 2 of the lengthened members. The construction structure 1 has frame members 4, 4 fixed to ends of the lengthened members 2, respectively, and a plate member 5 fixed to respective sides of the lengthened members 2. In the present embodiment, the construction structure 1 is a wall.

Each of the lengthened members 2 has supporting surfaces 21, 21 for supporting one of the panels 3 and different one of the panels 3, respectively, at both sides in the widthwise direction of the member 2. Specifically, the lengthened member 2 has a cross section in a rectangular form. Any adjacent two of the lengthened members 2 are arranged to face one of the supporting faces 21 of one of the two members 2 to one of the supporting faces 21 of the other member 2. In the present embodiment, the lengthened members 2 are each a column, and the column is arranged to make the longitudinal direction thereof parallel to the height direction thereof.

Each of the panels 3 is formed into a rectangular parallelepiped form. In the state that the panel 3 is fitted to between adjacent ones 2, 2 of the lengthened members, the longitudinal direction of the panel 3 is parallel to the longitudinal direction of the lengthened members 2. The widthwise direction of the panel 3 is parallel to the widthwise direction of the lengthened members 2.

In the present invention, a direction parallel to the longitudinal direction of the lengthened members 2 is called a first direction D1 of each of the construction structure 1, the lengthened members 2 and the panels 3; a direction parallel to the direction in which the lengthened members 2 are arranged side by side is called a second direction D2 of each of the construction structure 1, the lengthened members 2 and the panels 3; and a direction orthogonal to the first direction D1 and the second direction D2 is called a third direction D3 of each of the construction structure 1, the lengthened members 2 and the panels 3.

In other words, in the present embodiment, the first direction D1 of the panels 3 is the longitudinal direction (lengthwise direction) of the panels 3; the second direction D2 of the panels 3 is the widthwise direction of the panels 3; and the third direction D3 of the panels 3 is the thickness direction of the panels 3. Hereinafter, signs D1, D2 and D3 are attached, respectively, to respective directions corresponding to the first to third directions D1 to D3.

As illustrated in FIGS. 3 and 4, the panels 3 are each made of a synthetic resin (for example, a urethane resin, styrene resin or phenolic resin), and are each a foam having elasticity. Specifically, the panel 3 is a foam having a plurality of cells 31 formed lengthwise along a direction orthogonal to the widthwise direction D2 to have elasticity in the widthwise direction D2.

In the present invention, it is unnecessary that all the cells 31 are lengthwise formed along the direction orthogonal to the second direction D2. For example, it is sufficient for a half or more of the cells 31 to be lengthwise formed along the direction orthogonal to the second direction D2 to cause the panels 3 to have elasticity in the second direction D2. In other words, as far as the panels 3 have elasticity in the second direction D2, some of the cells 31 may be located to be formed along the direction parallel to the second direction D2 in the present invention.

The panels 3 are each formed to make the elastic modulus of the panel 3 in the widthwise direction D2 smaller than that in the longitudinal D1. The panel 3 is formed to make the elastic modulus of the panel 3 in the widthwise direction D2 substantially equal to that in the thickness direction D3.

Specifically, in the panel 3, the cells 31 are lengthwise formed along the longitudinal direction D1 out of directions orthogonal to the widthwise direction D2, thereby being formed to make the elastic modulus of the panel 3 in the widthwise direction D2 smaller than that in the longitudinal direction D1. More specifically, the cells 31 are located to arrange the respective maximum-dimension directions of the cells along the longitudinal direction D1, thereby making the respective elastic moduli in the widthwise direction D2 and the thickness direction D3 of the panel 3 smaller than that in the longitudinal direction D1 of the panel 3

The elastic modulus is the following ratio when external force is applied to the panel 3 to deform the panel 3: the ratio between the stress and the strain (deformation amount) of the panel in an elastic range of the panel. In other words, as the panel is smaller in elastic modulus, the panel becomes larger in deformation amount at the same stress (pressure).

When the panel 3 does not deform elastically, the dimension W2 in the widthwise direction D2 of the panel 3 is larger than the separate distance W1 between adjacent ones 2, 2 of the lengthened members. Thus, in the state that the panel 3 is compressed and deformed in the widthwise direction D2, the panel 3 is fitted to between the lengthened members 2, 2. The dimension W2 in the widthwise direction D2 of the panel 3 that does not deform elastically is preferably from 101 to 115% of the separate distance W1 between the lengthened members 2,2, more preferably from 105 to 110% thereof.

In the present embodiment, the panel 3 is a polyurethane foam panel. The structure of the panel 3 will be described in detail hereinafter.

The panel 3 is a polyurethane foam panel which is obtained by mixing a polyol composition comprising one or more polyol compounds and a water as a foaming agent with a polyisocyanate component, and causing these components to react with each other, and which has a lengthwise direction (longitudinal direction) D1, a widthwise direction D2, and a thickness direction D3. In the panel 3, the foam density is 15 kg/m³ or less, and the ratio of the 10% compressive strength S_(D1) in the lengthwise direction D1 to the 10% compressive strength S_(D2) in the widthwise direction D2 (S_(D1)/S_(D2)) is set to 2 or more.

The foam density (core density) of the panel 3 is preferably 15 kg/m³ or less, more preferably 13 kg/m³ or less, even more preferably 11 kg/m³ or less. The foam density is set into this range, for example, by adjusting the water as the foaming agent into the range of 20 to 100 parts by weight (for 100 parts by weight of the polyol compound(s)). The foam density is a value measured in accordance with JIS K7222.

The foam density of the panel 3 is 15 kg/m³ or less to be very low. Thus, the panel 3 has a high foaming expansion ratio. Accordingly, the cells 31 are each stretched into the lengthwise direction D1 to be made into an elliptic form. The long diameter direction of the cell 31 in the elliptic form becomes parallel to the lengthwise direction D1 of the panel 3, so that the panel 3 becomes high in foam strength in the lengthwise direction D1 while the panel 3 becomes low in foam strength in the widthwise direction D2 and the thickness direction D3 of the panel 3. As a result, the panel 3 has elasticity (flexibility) in the widthwise direction D2 and the thickness direction D3.

The panel 3 is formed to set the ratio of the 10% compressive strength S_(D1) in the lengthwise direction D1 to the 10% compressive strength S_(D2) in the widthwise direction D2 (S_(D1)/S_(D2)) to 2 or more. The ratio of the 10% compressive strength S_(D1) in the lengthwise direction D1 to the 10% compressive strength S_(D2) in the widthwise direction D2 (S_(D1)/S_(D2)) is preferably 3 or more, more preferably 5 or more in order to make the panel compatible between workability when the panel 3 is fitted to between the lengthened members 2, 2 and self-standing performance when the panel 3 is being fitted thereto. The upper limit of this ratio (S_(D1)/S_(D2)) is not particularly limited, and is, for example, about 7. The wording “X% compressive strength” denotes a stress necessary for compressing the panel 3 to be deformed by an amount of X%.

In order to improve the workability when the panel 3 is fitted to between the lengthened members 2, 2, it is necessary that the panel 3 can easily be compressed in the widthwise direction D2. Accordingly, the 10% compressive strength S_(D2)in the widthwise direction D2 of the panel 3 is preferably 3 N/cm² or less, more preferably 1 N/cm² or less, in particular preferably 0.5 N/cm² or less.

In order to improve the workability when the panel 3 is fitted to between the lengthened members 2, 2, it is also necessary that the compressed panel 3 is rapidly restored. It is therefore preferred that even when compressed in the widthwise direction D2 by 20%, the panel 3 is neither damaged nor broken, and further after compressed in the widthwise direction D2 by 20%, the panel 3 is restored into a dimension of 90% or more of the pre-compression dimension in the widthwise direction D2 of the panel when released from the compression.

In the panel 3, it is preferred that the foaming direction of the cells 31 is substantially perpendicular to each of the widthwise direction D2 and the thickness direction D3. The wording “substantially perpendicular” specifically denotes 90°±15°, in particular, 90°±10°. The wording “foaming direction of the cells” denotes the following when the shape of the individual cells 31 is regarded as an elliptical shape: the long diameter direction of the cells. The wording denotes, in particular, the direction obtained in the case of measuring a central region of the panel 3 (region extended from the center of the panel in the lengthwise direction D1 and the widthwise direction D2 to both sides thereof along the former direction D1 by 10% of the dimension in the former direction D1 of the panel, as well as to both sides thereof along the latter direction D2 by 10% of the dimension in the latter direction D2 thereof.

Since the panel 3 is used as a heating insulating member, the thermoconductivity λ of the panel 3 is preferably 0.04 W/m·K, or less. In this case, even when the panel 3 is a panel made low in density, the panel 3 can exhibit a sufficient heat insulating performance. The thermoconductivity herein is a value measured in accordance with JIS A1412-2.

The independent cell proportion of the panel 3 is preferably 15% or less, more preferably from 0 to 10%. When the panel is made high in continuous cell proportion in this way, the panel can ensure an excellent dimension stability. The independent cell proportion herein is a value measured in accordance with ASTM D2856.

As described above, the panel 3 is obtained by mixing a polyol composition containing one or more polyol compounds and a water as a foaming agent with a polyisocyanate component, and causing these components to react with each other.

The polyol compound(s) preferably include(s) a polyether polyol (A) that is a polymer having an average functional group number of 2 to 4 and a weight-average molecular weight of 3000 to 8000 and made from an alkylene oxide, and a short glycol (B) having a molecular weight less than 250.

The polyether polyol (A) is a polyoxyalkylene polyol yielded by causing an alkylene oxide to undergo ring-opening addition polymerization to an initiator having 2 to 4 active hydrogen atoms.

Examples of the initiator include aliphatic polyhydric alcohols (for example, glycols such as ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, 1,4-butanediol, 1,3-butanediol, 1,6-hexanediol, neopentyl glycol, cyclohexylene glycol and cyclohexanedimethanol, triols such as trimethylolpropane and glycerin, and tetrafunctional alcohols such as pentaerythritol); aliphatic amines (for example, alkylenediamines such as ethylenediamine, propylenediamine, butylenediamine, hexamethylenediamine and neopentyldiamine, and alkanolamines such as monoethanolamine and diethanolamine); and aromatic amines (for example, 2,4-toluenediamine, 2,6-toluenediamine, diethyltoluenediamine, 4,4′-diaminodiphenylmethane, p-phenylenediamine, o-phenylenediamine and naphthalenediamine). These compounds may be used alone or in any combination of two or more thereof. The initiator is preferably an aliphatic alcohol, more preferably a triol, even more preferably glycerin.

About the polyether polyol (A), the average functional group number is from 2 to 4, more preferably from 2.5 to 3.5. About the polyether polyol (A), the weight-average molecular weight thereof is more preferably from 3000 to 5000.

Examples of the alkylene oxide include ethylene oxide, propylene oxide, 1,2-butylene oxide, 2,3-butylene oxide, styrene oxide, and cyclohexene oxide. It is preferred to use, out of these compounds, ethylene oxide and propylene oxide together, and cause these oxides to undergo ring-opening addition polymerization to the initiator. At this time, it is preferred to set the proportion of ethylene oxide (“ethylene oxide”/“ethylene oxide”+“propylene oxide”) into the range of 5 to 30%.

The hydroxyl value of the polyether polyol (A) is preferably from 20 to 100 mgKOH/g, more preferably from 30 to 60 mgKOH/g. If this hydroxyl value is less than 20 mgKOH/g, the viscosity ratio of the polyol composition to the polyisocyanate component is high so that when this composition is mixed with the polyisocyanate component, a stirring failure is caused. Conversely, if the value is more than 100 mgKOH/g, an appropriate toughness is not easily given to the resultant polyurethane foam. The hydroxide value is a value measured in accordance with JIS K1557-1:2007.

Examples of the short glycol (B), which has a molecular weight less than 250, include ethylene glycol (molecular weight: 62), propylene glycol (molecular weight: 76), diethylene glycol (molecular weight: 106), dipropylene glycol (molecular weight: 134), 1,4-butanediol (molecular weight: 90), 1,3-butanediol (molecular weight: 90), 1,6-hexanediol (molecular weight: 118), glycerin (molecular weight: 92), and tripropylene glycol (molecular weight: 192). Of these examples, preferred are diethylene glycol, dipropylene glycol and glycerin, and particularly preferred is diethylene glycol in order to make the foam high in resin strength with a higher certainty. The molecular weight of the short glycol (B) is preferably from 62 to 200 mgKOH/g, more preferably from 90 to 150 mgKOH/g.

It is preferred that the polyol composition used as one of the raw materials further contains, as one of the polyol compounds, a polyether polyol (C) having an average functional group number of 2 to 4 and a weight-average molecular weight of 3000 to 5000 and made from propylene oxide. The polyether polyol (C) is a polyoxyalkylene polyol obtained by causing only propylene oxide to undergo ring-opening addition polymerization to an initiator having 2 to 4 active hydrogen atoms. Examples of the initiator include above-mentioned aliphatic polyhydric alcohols, aliphatic amines, and aromatic amines. However, the initiator is not particularly limited. The initiator is in particular preferably glycerin.

The polyol composition used as one of the raw materials preferably contains 10 to 80 parts by weight of the polyether polyol (A) and 10 to 60 parts by weight of the short glycol (B) in 100 parts by weight of the polyol compounds, and more preferably contains 15 to 70 parts by weight of the polyether polyol (A) and 10 to 50 parts by weight of the short glycol (B) therein in order to attain the production of the polyurethane foam panel 3 excellent in heat insulating performance while the panel 3 is made low in density. When the polyol composition contains the polyether polyol (C), the composition preferably contains 10 to 30 parts by weight of the polyether polyol (A), 10 to 60 parts by weight of the short glycol (B) and 30 to 70 parts by weight of the polyether polyol (C), and more preferably contains 15 to 25 parts by weight of the polyether polyol (A), 10 to 50 parts by weight of the short glycol (B) and 40 to 60 parts by weight of the polyether polyol (C).

Water is blended as a foaming agent into the polyol composition. The foaming agent is preferably water alone. The blend amount thereof is from 20 to 100 parts by weight for 100 parts by weight of the polyol compound(s), more preferably from 30 to 90 parts by weight therefor, even more preferably from 40 to 80 parts by weight therefor. Such a blend of water in a large amount makes it possible to make the panel 3 low in density.

Usually, a flame retardant, a catalyst and a foam adjustor are further blended into the polyol composition. Moreover, thereinto may be further blended a colorant, an antioxidant, and various other additives.

Examples of the flame retardant include organic phosphates, halogen-containing compounds, and metal compounds such as aluminum hydroxide. Particularly preferred are organic phosphates since these compounds have an effect of lowering the viscosity of the polyol composition. Examples of the organic phosphates include halogenated alkyl esters of phosphoric acid, alkyl esters of phosphoric acid, aryl esters of phosphoric acid, and phosphonates. Specific examples thereof include tris(chloropropyl) phosphate (TMCPP, manufactured by Daihachi Chemical Industry Co., Ltd.), tributoxyethyl phosphate (TBEP), tributyl phosphate, triethyl phosphate, trimethyl phosphate, and cresyldiphenyl phosphate. The blend amount of the flame retardant is preferably from 10 to 50 parts by weight, more preferably from 15 to 40 parts by weight for 100 parts by weight of the polyol compound(s). In order to prevent the brittleness-deterioration of the foam, it is particularly preferred that the polyol composition contains the flame retardant in an amount of 20 parts or more by weight for 100 parts by weight of the polyol compound(s), besides the polyether polyol (A) and the short glycol (B).

The catalyst is not particularly limited as far as the catalyst is a catalyst for promoting the urethanizing reaction. The catalyst is preferably a reactive amine catalyst, which can react with isocyanate groups of the polyisocyanate component. Examples of the reactive amine catalyst include N,N-dimethylethanolamine, N,N-dimethylaminoethoxyethanol, N,N, N′-trimethylaminoethylethanolamine, N,N,N′,N′-tetramethyl-2-hydroxypropylenediamine, N-hydroxyethylmorpholine, N-methyl-N-hydroxyethylpiperazine, and N,N-dimethylpropylenediamine.

An ordinary tertiary amine catalyst is also usable. Examples of the tertiary amine catalyst include N,N,N′,N′-tetramethylethylenediamine, N,N,N′,N′-tetramethylhexamethylenediamine, N,N,N′,N′,N″-pentamethyldiethylenetriamine, diazabicycloundecene, N,N-dimethylcyclohexylamine, triethylenediamine, and N-methylmorpholine.

The blend amount of the catalyst is preferably from 2 to 10 parts by weight, more preferably from 3 to 8 parts by weight for 100 parts by weight of the polyol compound(s).

The foam adjustor may be, for example, the following out of known foam adjustors for a polyurethane foam: a graft copolymer made from a polyoxyalkylene glycol, which is a polymer made from ethylene oxide or propylene oxide, and a polydimethylsiloxane. The foam adjustor is preferably a silicone foam adjustor in which the content by percentage of oxyethylene groups in a polyoxyalkylene is from 70 to 100% by mole. Specific examples thereof include products SH-193, SF-2937F and SF-2938F (manufactured by Dow Corning Toray Co., Ltd.), B-8465, B-8467 and B-8481 (manufactured by Evonik Degussa Japan Co., Ltd.), and L-6900 (manufactured by the company Momentive). The blend amount of the foam adjustor is preferably from 1 to 10 parts by weight for 100 parts by weight of the polyol compound(s).

The polyisocyanate component, which is mixed with the polyol composition to be caused to react therewith, thereby producing the polyurethane foam panel 3, maybe a polyisocyanate compound that has two or more isocyanate groups and that may be of various types, such as aromatic, alicyclic and aliphatic types. The polyisocyanate component is preferably a liquid diphenylmethane diisocyanate (MDI) since this compound is easy to handle, large in reaction rate and low in costs, gives a polyurethane foam excellent in physical properties, and produces other advantages. Examples of the liquid MDI include crude MDIs (c-MDIs) (“44V-10, 44V-20, etc.” (manufactured by Sumitomo Bayer Urethane Co., Ltd.), “MILLIONATE MR-200” (manufactured by Nippon Polyurethane Industry Co., Ltd.,), and urethonimine-containing MDIs “MILLIONATE MTL” (manufactured by Nippon Polyurethane Industry Co., Ltd.,). Together with the liquid MDI, a different polyisocyanate compound may be used. As the polyisocyanate compound used together therewith, a polyisocyanate compound known in the technical field of polyurethanes is usable without any restriction.

When the polyisocyanate component is mixed with the polyol composition to be caused to react therewith for the panel 3, the isocyanate index (NCO index) is set preferably to 30 or less, more preferably to less than 30. The lower limit of the isocyanate index is, for example, 20. By setting the isocyanate index into the range, the polyurethane foam panel 3 can be rendered a panel low in density and excellent in elasticity and heat insulating performance. The isocyanate index herein denotes an index representing, in the unit of percentage, the ratio by equivalent of isocyanate groups of the polyisocyanate component to all active hydrogen groups (provided that a calculation therefor is made under a condition that water as the foaming agent is regarded as a bifunctional active hydrogen compound) contained in the polyol composition (the ratio of the equivalent of the isocyanate groups to 100 equivalents of the active hydrogen groups).

A method for producing the panel 3 is preferably a method for producing the panel 3 that is a polyurethane foam panel obtained by using, as a raw material therefor, a foaming stock solution composition which contains a polyol composition containing one or more polyol compounds and water as a foaming agent, and further which contains a polyisocyanate component, in which: the polyol composition contains, as the polyol compound(s), for example, polyol compounds including a polyether polyol (A) that is a polymer made from an alkylene oxide and has an average functional group number of 2 to 4 and a weight-average molecular weight of 3000 to 8000, and a short glycol (B) having a molecular weight less than 250; water is contained in an amount of 20 to 100 parts by weight for 100 parts by weight of the polyol compounds; and when the polyisocyanate component is mixed with the polyol composition to be caused to react therewith, the isocyanate index is less than 30. In order to form a plurality of cells 31 lengthwise in the lengthwise direction D1 of the panel 3 to cause the panel 3 to have elasticity in the widthwise direction D2, the method preferably has, as illustrated in FIG. 5, an injecting step of injecting the foaming stock solution composition into a mold 7 having the above-defined lengthwise direction D1, widthwise direction D2 and thickness direction D3 to render planes (of the resultant panel) extended along the widthwise direction D2 and the thickness direction D3 a bottom surface 71 thereof; and a reaction step of subjecting the foaming stock solution composition after the injecting step to reaction.

Specifically, in the method for producing the panel 3, the foaming stock solution composition, which contains the polyol composition and the polyisocyanate component, is injected from a mixing head 8 to render the surface (of the resultant panel) extended in the widthwise direction D2 and the thickness direction D3 the bottom surface 71 (injecting step). After the injection, the foaming stock solution composition is subjected to reaction while foamed (or expended) in the lengthwise direction D1. In this way, a foam is formed (reaction step). In this reaction step, the mold 7 may be wholly or locally heated as required.

The configuration of the construction structure 1 according to the present embodiment is as described above, and a description will next be described about a method for producing the construction structure 1 according to the embodiment with reference to FIG. 6.

As illustrated in FIG. 6, plural lengthened members 2, 2 are arranged side by side in the widthwise direction D2 to make the respective longitudinal directions D1 parallel to each other. When external force is applied to each panel 3, the panel 3 is compressed in the widthwise direction D2. In this way, the dimension W2 in the widthwise direction D2 of the panel 3, which is larger than the separate distance W1 between the lengthened members 2, 2, is made smaller than the separate distance W1 between the lengthened members 2, 2.

The panel 3 compressed in the widthwise direction D2 is positioned between the lengthened members 2, 2, and then the applied external force is cancelled to restore the panel 3. Even after the panel 3 is brought into contact with respective supporting surfaces 21 of the lengthened members 2, the panel 3 is forced to be further restored by elasticity. Thus, in the state that the panel 3 contacts the lengthened members 2 adjacent thereto closely and further pushes the lengthened members 2, the panel 3 is fitted to between the lengthened members 2, 2.

As described above, in the construction structure 1 according to the present embodiment, the lengthened members 2 are located to make individual longitudinal directions of the members 2 parallel to each other in the first direction D1 and to be arranged side by side in the second direction 2 orthogonal to the first direction D1. The panels 3 are each a foam, which has the cells 31 formed lengthwise along the direction orthogonal to the second direction D2, to have elasticity in the second direction D2.

Accordingly, each of the panels 3 compressed in the second direction D2 is released from the compression between adjacent ones 2, 2 of the lengthened members to be restored. In this way, the panel 3 is fitted to between the lengthened members 2, 2 in the state of adhering closely to the (adjacent) lengthened members 2 and pressing the (adjacent) lengthened members 2. Thus, in the construction structure 1 according to the present embodiment, the panels 3 can each be fitted with ease to between the lengthened members 2, 2, and further the generation of any gap can be prevented between the panels 3 and the lengthened members 2.

Moreover, according to the construction structure 1 of the present embodiment, the cells 31 are formed lengthwise along the direction orthogonal to the second direction D2, so that the panel 3 is small in elastic modulus in the second direction D2. Thus, the panel 3 is easily compressed in the second direction D2 since the panel 3 has elasticity in the second direction D2.

Furthermore, the cells 31 are lengthwise formed along the first direction D1 out of directions orthogonal to the second direction D2, so that the panel 3 is large in elastic modulus in the first direction D1. Thus, the panel 3 has rigidity in the first direction D1; thus, the panel 3 fitted to between the lengthened members 2, 2 is stably held between the lengthened members 2, 2, so that the panel 3 can alone stand.

Additionally, the cells 31 are lengthwise formed along the first direction D1 out of the directions orthogonal to the second direction D2, so that the panel 3 can be improved in heat insulating performance in the third direction D3.

The present invention is not limited to the configuration of the above-mentioned embodiment. Effects and advantages thereof are not limited to the above-mentioned effects and advantages. Of course, in the invention, the embodiment may be variously modified as far as the modified embodiments do not depart from the subject matters of the invention. For example, it is needless to mention that any constituent or manner, or any other that is related to various modified examples that will be described below may be selected at will to be adopted for one of the constituents, manners and others that are related to the above-mentioned embodiment.

The construction structure 1 according to the above-mentioned embodiment has a configuration in which each of the panels 3 is fitted to between adjacent ones 2, 2 of the lengthened members. However, the present invention is not limited to this configuration. As illustrated in FIG. 7, the invention may have, for example, a configuration in which panels 3 are arranged side by side in the first direction D1, and are each fitted to between adjacent ones 2, 2 out of lengthened members. As illustrated in FIG. 8, the invention may have a configuration in which panels 3 are arranged side by side in the second direction D2, and are each fitted to between adjacent ones 2, 2 out of lengthened members.

When the construction structure shown in FIG. 7, which is a construction structure 1, is formed to render the first direction D1 a height direction thereof, it is preferred that each of the panels 3 is formed to make the elastic modulus in the widthwise direction D2 smaller than that in the longitudinal direction D1 by forming cells 31 lengthwise along the first direction D1. In this way, the panel 3 has rigidity in the first direction D1. Thus, the panel 3 fitted to between the lengthened members 2, 2 can alone stand, and further the panel 3 can stably support a panel arranged above the panel 3, out of the panels 3, from below the above-arranged panel.

In the construction structure illustrated in FIG. 8, which is a construction structure 1, adjacent ones 32, 32, out of ends of the panels, contact each other at a position outside the position between the lengthened members 2, 2. Panel ends 33, 33 at respective sides of the panels that are reverse to the end 32, 32 sides thereof are each positioned between the lengthened members 2, 2, and contact the lengthened members 2, 2 and a plate member 5. When the panels 3 receive external force to position the adjacent panel ends 32, 32 between the lengthened members 2, 2, the panels 3 are fitted to between the lengthened members 2, 2 while compressed in the second direction D2.

The construction structure 1 according to the above-mentioned embodiment has a configuration in which each of the panels 3 is formed to make the dimension in the first direction D1 larger than that in the second direction D2. However, the present invention is not limited to this configuration. As has been illustrated in FIG. 7, the invention may have, for example, a configuration in which each of the panels 3 is formed to make the dimension in the first direction D1 smaller than that in the second direction D2.

The above-mentioned embodiment has a configuration in which the lengthened members 2 are columns, and the construction structure 1 is a wall. However, the present invention is not limited to this configuration. The invention may have, for example, a configuration in which the lengthened members 2 are each a floor stringer in which the first direction (longitudinal direction) D1 is a horizontal direction, and the construction structure 1 is a floor. The invention may have a configuration in which the lengthened members 2 are each a ceiling stringer in which the first direction (longitudinal direction) D1 is a horizontal direction, and the construction structure 1 is a ceiling. Furthermore, the invention may have a configuration in which the lengthened members 2 are each a rafter in which the first direction (longitudinal direction) D1 is a direction inclined to vertical and horizontal directions, and the construction structure 1 is a roof. In short, in the invention, the first to third directions D1, D2 and D3 are not limited to specified directions.

In the above-mentioned embodiment, the panels 3 are produced, using the mold 7. However, the present invention is not limited to this manner. In the invention, for example, the foaming stock solution composition is sprayed onto a conveyer, and the panels 3 are cut into the form of rectangular parallelepipeds to render the vertical direction the first direction D1 thereof.

As illustrated in FIG. 9, the present invention may have a configuration in which each of two ends in the second direction D2 of each panel 3 has a taper portion 34 inclined to the third direction D3. The panel 3 is formed to make the dimension thereof in the second direction D2 gradually large by the taper portion 34. By pushing the panel 3 in the third direction D3, the panel 3 is fitted to between adjacent ones 2, 2 out of lengthened members 2 while compressed in the second direction D2. The taper portion 34 maybe located in only one of the (two) ends.

As illustrated in FIG. 10, the present invention may have a configuration in which fixing portions 6 are located to be projected in the second direction D2 from lengthened members 2, ones opposed to each other out of the fixing portions 6 being for fixing a panel 3 fitted to between adjacent ones 2, 2 of the lengthened members. The opposed fixing portions 6 each have an engaging moiety 61 with which the panel 3 fitted to between the adjacent lengthened members 2, 2 is engaged in the second direction D2, and an inclined moiety 62 inclined to the third direction D3.

According to this configuration, the panel 3 is pushed in the third direction D3 to be compressed into the second direction D2 through the respective inclined moieties 62 of the opposing fixing portions 6. The panel 3 rides over the opposing fixing portions 6 to be fitted to between the lengthened members 2, 2. The panel 3 fitted to between the lengthened members 2, 2 is engaged with the opposed fixing portions 6 to be prevented from dropping away from between the lengthened members 2, 2.

The present invention may have a configuration in which the front surface of each panel 3 is covered with a film (for example, a shrinkable film made of polyvinyl. This configuration makes the panel 3 easy to handle when the panel 3 is held by worker's hand or the panels 3 are stacked onto each other.

EXAMPLES

Hereinafter, the present invention will be described in more detail by way of examples thereof. However, the invention is not limited to these examples.

Preparation of Polyol Compositions

Formulations shown FIG. 11 were each used as raw materials for a polyurethane foam panel 3 species to prepare a polyol composition. Details of the individual components shown in FIG. 11 are as follows:

(1) Polyol compounds

Polyether polyol (A)-1: trade name “EXCENOL-820” (manufactured by Asahi Glass Co., Ltd.), i.e., a polyether polyol (weight-average molecular weight=4900; hydroxyl value (OHV)=34 mgKOH/g) obtained by addition-polymerizing ethylene oxide and propylene oxide, using glycerin as an initiator,

Polyether polyol (A)-2: trade name “EXCENOL-850” (manufactured by Asahi Glass Co., Ltd.), i.e., a polyether polyol (weight-average molecular weight=7000; hydroxyl value (OHV)=25 mgKOH/g) obtained by addition-polymerizing ethylene oxide and propylene oxide, using glycerin as an initiator,

Short glycol (B)-1: diethylene glycol (DEG) (manufactured by Nacalai Tesque, Inc.; molecular weight=106, and hydroxyl value (OHV)=1058 mgKOH/g), and

Polyether polyol (C): trade name “T-3000S” (manufactured by Mitsui Chemicals, Inc.), i.e., a polyether polyol (weight-average molecular weight=3000; hydroxyl value=56 mgKOH/g) obtained by addition-polymerizing only propylene oxide, using glycerin as an initiator.

(2) Flame retardant: trade name “TMCPP” (manufactured by Daihachi Chemical Industry Co., Ltd.)

(3) Foam adjustor:

Foam-adjustor-1: silicone nonionic surfactant, i.e., trade name “SF-2938F” (manufactured by Dow Corning Toray Co., Ltd.)

(4) Catalysts

Catalyst-1: tertiary amine catalyst, i.e., trade name “TOYOCAT-ET” (manufactured by Toso Co., Ltd.), and

Catalyst-2: N,N-dimethylaminoethoxyethanol, i.e., trade name “KAO No. 26” (manufactured by Kao Corp.).

Panel Evaluation Examples 1 to 3

Using a polyol composition prepared in accordance with a formulation shown in FIG. 11, and a polyisocyanate component (c-MDI (“SUMIDULE 44V-10”, manufactured by Sumitomo Bayer Urethane Co., Ltd.); NCO%: 31%) (in each of these examples), a foaming stock solution composition was prepared which had an isocyanate index (NCO index) adjusted as shown in FIG. 11. This composition was injected from the mixing head 8 onto the bottom surface 71 of the mold 7 shown in FIG. 5 (the dimension in the lengthwise direction D1: 900 mm; the dimension in the widthwise direction D2: 500 mm; and the dimension in the thickness direction D3: 500 mm). Thereafter, a polyurethane foam panel 3 obtained by subjecting the foaming stock solution composition to reaction was cut into pieces on cutting planes of the foam panel 3 along the lengthwise direction D1 and the widthwise direction D2. In this way, panels 3 were produced about each of which the panel thickness direction D3 was substantially perpendicular (90°) to the foaming direction of the cells 31 (the dimension of the panel 3 in the lengthwise direction D1: 700 mm; the dimension of the panel 3 in the widthwise direction D2: 400 mm; and the dimension of the panel 3 in the thickness direction D3: 60 mm). Results thereabout are shown in Table 1.

Weight-Average Molecular Weight

The weight-average molecular weight (of any polymer in each of the examples) was obtained by making a measurement therefor by GPC (gel permeation chromatography) and then calculating out a value in terms of that of standard polystyrene.

GPC apparatus: LC-10A, manufactured by Shimadzu Corp.

Columns: the use of the following three columns linked to each other: columns (PLgel, 5 μm, 500 Å), (PLgel, 5 μm, 100 Å) and (PLgel, 5 μm, 50 Å) manufactured by Polymer Laboratories Ltd.

Flow rate: 1.0 mL/min.

Concentration: 1.0 g/L

Injected amount: 40 μL

Column temperature: 40° C.

Eluent: Tetrahydrofuran

Foam Density

The foam density (in the example) was obtained in accordance with JIS K 7222.

Thermoconductivity

The thermoconductivity of any one of the panels 3 (of the example) in the thickness direction D3 was measured in accordance with JIS A1412-2 (Method for Measuring Thermal Resistance and Thermoconductivity of Heat Insulating Material—Section 2: Heat Flow Meter Method) (HFM method) on the basis of JIS A9526 (Spray-Applied Rigid Urethane Foam for Thermal Insulation for Buildings).

10% Compressive Strength

A cube 50 millimeters square was cut out as a foam specimen from a central region of any one of the polyurethane foam panels 3 (the dimension in the lengthwise direction D1: 700 mm; the dimension in the widthwise direction D2: 400 mm; the dimension in the thickness direction D3: 60 mm) produced by the above-mentioned method (in the example) (the central region: region extended from the center of the panel in the lengthwise direction D1 and the widthwise direction D2 to both sides thereof along the former direction D1 by 10% of the dimension in the former direction D1 of the panel, as well as to both sides thereof along the latter direction D2 by 10% of the dimension in the latter direction D2 thereof). An autograph, AG-X plus (manufactured by Shimadzu Corp.) was used to measure the 10% compressive strength of the specimen at a compression rate of 5 mm/min.

Fitting Workability of Each Polyurethane Foam Panel for Being Fitted into Predetermined Shape

When any one of the panels 3 (of the example), the dimension of which was 400 mm in the widthwise direction D2, was compressed into the widthwise direction D2 by 5% to be easily fittable to between adjacent ones 2, 2, out of lengthened members, having a separate distance of 380 mm, the panel was judged to have a flexibility for the predetermined width. Thus, this panel 3 was judged to be good in fitting workability (“◯” in FIG. 11).

From the results in FIG. 11, it is understood that the panels 3 of each of Examples 1 to 3 are low in density and small in brittleness, and have an excellent heat insulating performance in the thickness direction D3. It is also understood that the panels 3 each have a difference in compressive strength between the lengthwise direction D1 and the lateral direction D2 and further have an excellent flexibility in the widthwise direction D2 to be excellent also in fitting workability.

DESCRIPTION OF REFERENCE SIGNS

1: Construction structure, 2: Lengthened member, 3: Panel, 4: Frame member, 5: Plate member, 6: Fixing portion, 7: Mold, 8: Mixing head, 21: Supporting surface, 31: Cell, 32: Panel end, 33: Panel end, 34: Taper portion, 61: Engaging moiety, 62: Inclined moiety, 71: Bottom surface, D1: First direction, D2: Second direction, and D3: Third direction. 

1. A construction structure, comprising: a plurality of lengthened members located to make individual longitudinal directions of the members parallel to each other in a first direction and to be arranged side by side in a second direction orthogonal to the first direction; and a panel fittable to between the lengthened members; wherein the panel is a foam having a plurality of cells formed lengthwise along a direction orthogonal to the second direction to have elasticity in the second direction.
 2. The construction structure according to claim 1, wherein the cells are formed lengthwise along the first direction to make the elastic modulus in the second direction of the panel smaller than that in the first direction of the panel.
 3. A method for producing a construction structure, comprising: preparing a plurality of lengthened members located to make individual longitudinal directions of the members parallel to each other in a first direction and to be arranged side by side in a second direction orthogonal to the first direction; and fitting a panel to between the lengthened members, the panel being a foam having a plurality of cells formed lengthwise along a direction orthogonal to the second direction to have elasticity in the second direction. 